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MERLIN 6000
Thermal Dynamics MERLIN 6000 - User Manual
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Manual No. 0-2568
October 6, 1999
MERLIN
®
6000
Plasma Cutting
Master P
o
wer Suppl
y
Operating Manual
A-01497
2
Table of Contents
Main Page
Table of Contents
3
General Information
5
Notes, Cautions and Warnings
5
Important Safety Precautions
5
Publications
6
Note, Attention Et Avertissement
7
Precautions de Securite Importantes
7
Documents de Reference
9
Declaration of Conformity
11
Statement of Warranty
12
Introduction & Description
13
Scope of Manual
13
General Description
13
Specifications & Design Features
14
Theory of Operation
15
Options and Accessories
16
Installation Procedures
17
Introduction
17
Site Location
17
Unpacking
17
Removing Skid
17
Section 3 Installation Procedures
17
Filling Master Power Supply Coolant
18
Input Power Connections
18
Voltage Selection
19
Primary Power Cable Connections
20
Work Cable and Ground Connections
20
Plasma and Secondary Gas Connections
21
Connecting Torch Supply Leads
26
External Cable Connections
28
Master/Slave Parallel Cable Connection
30
Lifting Options
30
Pilot Resistor Adjustment
31
Operation
35
Introduction
35
Operation Section
35
Functional Overview
35
Front and Rear Panel Descriptions
35
Operating Unit Without Gas Control Option
38
Operating Unit with Gas Control Option
40
System Operation
41
Optional Power Supply Settings
42
Customer/Operator Service
47
Introduction
47
General Maintenance
47
Common Operating Faults
48
Troubleshooting
48
Basic Parts Replacement
51
Parts Lists
53
Introduction
53
Ordering Information
53
Complete Power Supply Replacement Parts List
54
Basic Component Replacement Parts List
55
Power Supply Options and Accessories
56
Appendix I: Input Wiring Requirements
57
Appendix II: Sequence of Operation Block Diagram
58
Appendix III: Typical Mechanized System Work and Ground Cable Connections
59
Appendix IV: Typical Mechanized System Cable Interconnection Diagram
60
Appendix V: Quick Reference to Interconnecting Cables and Hoses
62
Appendix VI: Interface Cable for Remote Control (Rc6010)
63
Appendix VII: Interface Cable for Standoff Control (Sc11)
64
Appendix VIII: Cnc Interface Cables
65
Appendix IX: Ladder Diagram - 120 Vac
66
Appendix X: Ladder Diagram - 15 VDC
67
Appendix XI: Parallel Cable
68
Appendix XII: Recommended Routine Maintenance Schedule for Water Cooled Plasma Cutting Systems
69
APPENDIX XIII: SYSTEM SCHEMATIC - Rev 'B' or Earlier
70
APPENDIX XIV: SYSTEM SCHEMATIC - Rev 'C' or Later
72
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Thermal Dynamics MERLIN 6000 Specifications
General
Brand
Thermal Dynamics
Model
MERLIN 6000
Category
Welding System
Language
English
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